US20160338778A1 - Tracked cartilage repair system - Google Patents
Tracked cartilage repair system Download PDFInfo
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- US20160338778A1 US20160338778A1 US15/224,734 US201615224734A US2016338778A1 US 20160338778 A1 US20160338778 A1 US 20160338778A1 US 201615224734 A US201615224734 A US 201615224734A US 2016338778 A1 US2016338778 A1 US 2016338778A1
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B34/00—Computer-aided surgery; Manipulators or robots specially adapted for use in surgery
- A61B34/10—Computer-aided planning, simulation or modelling of surgical operations
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B34/00—Computer-aided surgery; Manipulators or robots specially adapted for use in surgery
- A61B34/20—Surgical navigation systems; Devices for tracking or guiding surgical instruments, e.g. for frameless stereotaxis
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B90/00—Instruments, implements or accessories specially adapted for surgery or diagnosis and not covered by any of the groups A61B1/00 - A61B50/00, e.g. for luxation treatment or for protecting wound edges
- A61B90/90—Identification means for patients or instruments, e.g. tags
- A61B90/98—Identification means for patients or instruments, e.g. tags using electromagnetic means, e.g. transponders
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/30756—Cartilage endoprostheses
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/3094—Designing or manufacturing processes
- A61F2/30942—Designing or manufacturing processes for designing or making customized prostheses, e.g. using templates, CT or NMR scans, finite-element analysis or CAD-CAM techniques
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
- A61B17/16—Bone cutting, breaking or removal means other than saws, e.g. Osteoclasts; Drills or chisels for bones; Trepans
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
- A61B17/32—Surgical cutting instruments
- A61B17/320016—Endoscopic cutting instruments, e.g. arthroscopes, resectoscopes
- A61B17/32002—Endoscopic cutting instruments, e.g. arthroscopes, resectoscopes with continuously rotating, oscillating or reciprocating cutting instruments
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B34/00—Computer-aided surgery; Manipulators or robots specially adapted for use in surgery
- A61B34/10—Computer-aided planning, simulation or modelling of surgical operations
- A61B2034/101—Computer-aided simulation of surgical operations
- A61B2034/102—Modelling of surgical devices, implants or prosthesis
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B34/00—Computer-aided surgery; Manipulators or robots specially adapted for use in surgery
- A61B34/10—Computer-aided planning, simulation or modelling of surgical operations
- A61B2034/108—Computer aided selection or customisation of medical implants or cutting guides
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B34/00—Computer-aided surgery; Manipulators or robots specially adapted for use in surgery
- A61B34/20—Surgical navigation systems; Devices for tracking or guiding surgical instruments, e.g. for frameless stereotaxis
- A61B2034/2072—Reference field transducer attached to an instrument or patient
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B90/00—Instruments, implements or accessories specially adapted for surgery or diagnosis and not covered by any of the groups A61B1/00 - A61B50/00, e.g. for luxation treatment or for protecting wound edges
- A61B90/90—Identification means for patients or instruments, e.g. tags
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/929—Tool or tool with support
- Y10T83/9372—Rotatable type
Definitions
- the present disclosure relates to tissue repair and replacement. More particularly, the present disclosure relates to a surgical system for repairing a tissue defect and a method for utilizing the same.
- Damage to anatomical tissues may result from trauma, aging or disease, for example. Such damage may result in pain and/or restricted mobility, which in turn may necessitate surgical intervention to repair the damaged tissues.
- some anatomical tissues may require lengthy periods of time to heal or may have limited capability to heal on their own.
- tissue damage such as procedures for joint arthroplasty procedures in which one or more of the articular surfaces of the joint are replaced.
- a patch or plug of synthetic cartilage and/or bone is implanted in a void created by excision of the damaged tissue.
- Still other methods such as mosaicpiasty and osteochondral autograft transfer, harvest viable natural cartilage from one area of the body and implant it at the site of the excised damaged tissue.
- one potential method is to remove a cylinder of tissue large enough to encompass the defect, and then implant a pre-made prosthetic plug sized to fit the cylindrical void created by the resection.
- this method for elongate defects, such as hairline fractures or irregularly shaped diseased tissue profiles, may result in the removal of a large proportion of healthy tissue material
- smaller cylindrical excisions can be serially arranged along the extent of an elongate defect, and smaller cylindrical plugs can then be placed in a line along the resected area.
- the present disclosure provides a system and method for repairing an area of defective tissue which reduces the removal of healthy tissue at the margins of the defect.
- the system tracks the movement and function of a tissue resection tool within a monitored surgical space. This movement is continuously recorded to create a three-dimensional set of data points representative of the excised volume of tissue. This data set is then communicated to a custom implant forming device which creates a custom implant sized to fit the void created by the excision.
- the system and method of the present disclosure allows a surgeon to exercise intraoperative control over the specific shape, volume and geometry of the excised area. Moreover, the surgeon may utilize a “freehand” resection method to excise only that tissue deemed to be diseased and/or damaged, because the custom-formed implant will accommodate an irregularly-shaped resection volume.
- the present disclosure provides a system for repairing a tissue defect, the system comprising: a resection tool having an operative end adapted to resect anatomical tissue; at least one positional marker in a known spatial relationship to the resection tool, the at least one positional marker forming an emanated signal indicative of at least one of a position and an orientation of the operative end of the resection tool, such that movement of the resection tool creates a plurality of data points representative of a volume; a controller communicatively connected to the at least one positional marker and operable to receive the emanated signal, the controller including software adapted to translate the emanated signal into implant forming commands; and an implant forming system which utilizes the implant forming commands to form a custom implant sized to replicate the volume represented by the plurality of data points.
- the system provides a detector monitoring a surgical space, the detector operable to detect the emanated signal within the monitored surgical space, wherein the at least one positional marker generates the emanated signal.
- the system provides a detector monitoring a surgical space, the detector operable to detect the emanated signal within the monitored surgical space; and a signal generator producing an ambient signal within the monitored surgical space, wherein the at least one positional marker reflects at least a portion of the ambient signal to create the emanated signal.
- the present disclosure provides a method of repairing a tissue defect in an anatomical structure, the method comprising the steps of removing a portion of the anatomical structure to create a void having a first shape, the portion including the tissue defect; determining a second shape corresponding to the first shape of the void; and after the step of determining a second shape, manufacturing an implant having the second shape for placement within the void, the second shape generally matching the first shape.
- the present disclosure provides a method system for repairing a tissue defect within a monitored surgical space, the system comprising: means for resecting tissue to create a void having a void size and void shape, the means for resecting comprising: an operative end; and a positional marker in a known spatial relationship to the operative end; means for detecting movement of the positional marker within the monitored surgical space, the means for detecting movement producing a signal; means for converting the signal into implant forming commands; and means for using the implant forming commands to form a custom implant, wherein the custom implant has an implant size corresponding to the void size and an implant shape corresponding to the void shape.
- FIG. 1 is a perspective view of an embodiment of an orthopaedic system in accordance with the present disclosure, illustrating a custom implant formed to ill an irregularly shaped void;
- FIG. 2 a is a perspective view of a proximal portion of a tibia, in which the tibial articular surface has an elongate tissue defect;
- FIG. 2 b is a partial perspective view of the proximal tibia shown FIG. 2 a, illustrating an irregularly-shaped implant filling a correspondingly shaped void after excision of the tissue defect shown in FIG. 2 a;
- FIG. 3 is an elevation, section view of the proximal tibia shown in FIG. 2 a, illustrating a custom implant and optional shims;
- FIG. 4 a is a perspective view of a cutting instrument in accordance with the present disclosure.
- FIG. 4 b is a perspective view of another cutting instrument in accordance with the present disclosure.
- FIG. 5 is a flow chart of an exemplary method of the present disclosure
- FIG. 6 is a flow chart of another exemplary method of the present disclosure.
- FIG. 7 is a schematic view of an exemplary tracked cartilage repair system in accordance with the present disclosure.
- FIG. 8 is a is a schematic view of another exemplary tracked cartilage repair system in accordance with the present disclosure.
- FIG. 9 is a schematic view of yet another exemplary tracked cartilage repair system in accordance with the present disclosure.
- orthopaedic system 600 includes tracked tissue resection tool 602 , tracking system 619 , signal conversion system 620 , and custom implant forming system 630 .
- tracking system 619 monitors the movement of tool 602 .
- Data points indicative of the monitored cutter position are collected throughout the resection, rendering a set or “cloud” of data points bounding a virtual volume that is representative of void 712 .
- Tracking system 619 sends this data set to signal conversion system 620 , which in turn converts the data into implant forming commands 629 .
- Implant forming commands 629 are then sent to implant forming system 630 , which creates custom implant 700 sized and shaped to fill void 712 created by the resection of defective tissue 702 .
- orthopaedic system 600 is used to repair defect 702 ( FIG. 2 a ) located in tissue 704 at the proximal end of tibia 703 .
- orthopaedic system 600 may be used to repair other types of tissue, such as bone and non-articular forms of cartilage (such as elastic and fibro cartilage), and may be used for other anatomical surfaces, including but not limited to surfaces associated with the femur, distal tibia, pelvis, talus, glenoid, or humerus, for example.
- tissue resection tool 602 includes an operative end adapted to resect tissue, shown as mill 606 .
- Mill 606 is rotatably driven by power transmitted from a remote power source (i.e., an electrical outlet or compressed air reservoir, not shown) via power transmission cable 605 .
- Trigger 603 controls the delivery of power to mill 606 .
- Resection tool 602 can be said to be a “freehand” cutting tool, in that an operator can hold and maneuver handle 608 while manipulating trigger 603 to selectively resect defective tissue 702 ( FIG. 2 a ) in a freehand manner, as described in detail below.
- An exemplary cutting instrument suitable for use with the present system is described in U.S. Pat. No. 6,757,582, entitled METHODS AND SYSTEMS TO CONTROL A SHAPING TOOL, the entire disclosure of which is hereby expressly incorporated herein by reference.
- tissue resection tools 602 a, 602 b are hand-held instruments similar to tissue resection tool 602 , but have alternative operative ends.
- Tissue resection tool 602 a of FIG. 4 a includes oscillating blade 606 a
- resection tool 602 b of FIG. 4 b includes scalpel 606 b.
- the operative end of resection tool 602 may be any cutting tool or device capable of excising a quantity of tissue from an anatomical surface, such as a retractable blade, a particulate stream, a cautery device, a rotary cutting blade, a cartilage punch, or an ultrasonic cutting device, for example,
- tissue resection tool 602 may be modularly adaptable for use with any number of different operative ends.
- an operative end (such as mill 606 ) of resection tool 602 is in a known spatial relationship with tool positional marker 610 , which allows the spatial position and orientation of the operative end to be monitored.
- orthopaedic system 600 is adjusted to account for this new geometry.
- the user may input identifying information for the new operative end into computer 622 , such as by selecting from a pre-programmed list of known operative ends (i.e., “mill,” “oscillating blade” or “scalpel”).
- operative ends 606 , 606 a, 606 b may each include a unique identifier readable by resection tool 602 , such as a barcode, radio frequency identification (RFID) tag, or magnet.
- RFID radio frequency identification
- this identifier is sent to computer 622 automatically (i.e., via wireless transmission), obviating the need for the system user to input the information manually.
- tissue resection tools 602 , 602 a, 602 b are described and depicted herein as hand-held instruments suitable for freehand resections, alternate non hand-held embodiments of resection tool 602 are also contemplated.
- computer-controlled or haptic robotic arms may be used in conjunction with the present system, such as the system described in U.S. patent application Ser. No. 11/610,728, filed Dec. 14, 2006, entitled IMAGELESS ROBOTIZED DEVICE AND METHOD FOR SURGICAL TOOL GUIDANCE, and commonly assigned with the present application, the entire disclosure of which is hereby expressly incorporated herein by reference.
- orthopaedic system 600 further includes tracking system 619 for monitoring the position, orientation and movement of resection tool 602 within a tracked surgical space.
- tracking system 619 includes one or more resection tool positional markers 610 and detector 614 , which cooperate to generate data indicative of the position and orientation of mill 606 within a field of view of detector 614 , as described below.
- a single detector 614 is shown in FIG. 1 for simplicity, it is contemplated that multiple-detector systems may be used to monitor the surgical space.
- FIG. 7 an embodiment of tracking system 619 which monitors the position and orientation of resection tool 602 is schematically depicted.
- Resection tool positional marker 610 is coupled to resection tool 602 , such that the position of mill 606 is in a known (i.e., fixed or calculable) spatial relationship with marker 610 .
- detector 614 receives signals 612 emanating from positional marker 610 , and each received signal 612 provides a discrete parcel of data indicative of the position and orientation of mill 606 .
- One exemplary detector suitable for use with the present system is the POLARIS SPECTRA brand optical tracking system, which is produced by Northern Digital Inc., of Ontario, Canada (POLARIS SPECTRA is a registered trademark of Northern Digital Inc.). Because positional marker 610 internally generates and distributes signal 612 to detector 614 , tracking system 619 may be said to use an active data collection modality. Examples of internally generated signals 612 suitable for use with orthopaedic system 600 include visible light (e.g., light emitting diodes), fluoroscopic, infrared, radio frequency, electromagnetic, or ultrasonic forms of signals, and the like.
- internally generated signals may come from accelerometers, gyroscope-based sensors, inclinometers, and other signal generation devices described in U.S. patent application Ser. No. 12/410,884, filed Mar. 25, 2009 and entitled METHOD AND SYSTEM FOR PLANNING/GUIDING ALTERATIONS TO A BONE, and in U.S. patent application Ser. No. 12/410,854, filed Mar. 25, 2009 and entitled TRACKING SYSTEM AND METHOD, the entire disclosures of which are hereby incorporated herein by reference.
- movements of resection tool 602 are monitored by detector 614 , and recordation of such movements generates a set of data points representative of a volume of resected material.
- the data points which are clustered together within a virtual volume, can be said for form a “cloud” of data points as noted above.
- a first data point collected at a first three-dimensional coordinate can be said to represent a starting point of resection tool 602 .
- subsequent data points collected at subsequent three-dimensional coordinates can be said to represent a corresponding movement of resection tool 602 .
- this three-dimensional volume defined by the “cloud” of data points has a shape and size that mimics the three-dimensional volume of void 712 .
- this set or cloud of data points is subsequently used to create custom implant 700 such that implant 700 is sized and shaped to correspond to void 712 .
- tracking system 619 may include tibia position markers 609 ( FIG. 1 ) fixed to tibia 703 .
- FIG. 8 an embodiment of the orthopaedic system 600 in which tracking system 619 monitors the positions of both tibia 703 and resection tool 602 is schematically illustrated.
- the addition of tibial position monitoring allows movement of tibia 703 during the surgical procedure while preserving the ability to collect comprehensive and accurate data regarding the volumetric characteristics of void 712 ( FIG. 1 ) formed during resection of defective tissue 702 ( FIG. 2 a ).
- a set or cloud of data points is created during resection of defective tissue 702 .
- defective tissue 702 and resection tool 602 move also. If such movement is not accounted for, the three-dimensional coordinates of a data point collected before the movement will fail to properly correspond with the three-dimensional coordinates of a data point collected after the movement because the latter data point will be spaced from the former data point not only by the amount of movement of resection tool 602 , but also by the amount of movement of tibia 703 .
- Tracking the movement of tibia 703 allows the vector associated with a given movement of tibia 703 at a given time to be subtracted from the vector associated with the movement of resection tool 602 at the same time, thereby correcting for tibial movement and keeping the integrity of the data cloud intact.
- tibia position marker 609 includes an array of fiducials 609 a, which are collectively fixed to tibia 703 in a known (i.e., fixed or calculable) spatial relationship with tissue defect 702 .
- External signal generator 613 FIG. 8
- controller ambient signal 613 a in the tracked surgical space
- fiducials 609 a reflect ambient signal 613 a to produce reflected signal 613 b.
- position marker 609 includes four fiducials 609 a arranged in a generally planar configuration.
- the individual point signals emanating from each of the four fiducials 609 a define a planar quadrilateral shape, the position and orientation of which can be determined within the tracked surgical space.
- a single point signal can show movement but not changes in orientation.
- reflected signal 613 b emanating from positional marker 609 is indicative of the position and orientation of tibia 703 (and, thus, of tissue defect 702 ). Movement of tibia 703 is monitored by detector 614 in a similar manner as discussed above with respect to the monitored movement of resection tool 602 .
- ambient signal 613 a can be any signal capable of creating a reflected signal 613 b that is uniquely distinguishable from ambient signal 613 a by detector 614 .
- ambient signal 613 a may be altered to produce reflected signal 613 b by a change in frequency, wavelength, or shape of ambient signal 613 a, or by redirection of less than all of ambient signal 613 a. Exemplary systems and methods for passive data collection are described in U.S.
- FIG. 9 schematically illustrates orthopaedic system 600 having tracking system 619 ′, which utilizes only passive data collection for collection of data indicative of the position and orientation of mill 606 of resection tool 602 .
- tracking system 619 ′ includes signal generator 616 which generates ambient signal 617 , and further includes passive tool position marker 615 which is coupled to resection tool 602 in a known (i.e., fixed or calculable) spatial relationship to mill 606 .
- Passive tool position marker 615 is generally analogous to tibia position marker 609 , which includes an array of fiducials 609 a as described above. However, passive tool position marker 615 is fixed to resection tool 602 rather than tibia 703 . Upon interacting with passive tool position marker 615 , ambient signal 617 is altered and transmitted to detector 614 as reflected signal 618 . Signal generator 616 , ambient signal 617 and reflected signal 618 are generally analogous to generator 613 , ambient signal 613 a and reflected signal 613 b, discussed above, except for being adapted for use with resection tool 602 rather than tibia 703 .
- tracking system 619 may include systems utilizing any combination of active and passive data collection for acquiring data associated with mill 606 of resection tool 602 and/or tibia 703 .
- a “fully passive” system may include a combination of passive marker 609 ( FIGS. 1, 2 a and 8 ) affixed to tibia 703 , passive tool position marker 615 ( FIG. 9 ) coupled to resection tool 602 , and one or both of signal generators 613 , 616 ( FIGS. 8 and 9 ).
- Passive markers 609 , 615 may reflect one or more ambient signals (i.e., signals 613 a, 617 ) to create distinct reflected signals 613 b, 618 that are distinguishable from one another by detector 614 , or by separate individual detectors.
- Detector 614 thus receives any number of reflected or generated signals from the monitored surgical space, as described above. Turning again to FIG. 1 , these aggregated received signals pass from detector 614 to computer 622 via data input cable 605 a as detected signal 621 ( FIGS. 7-9 ). Detected signal 621 is received by signal conversion system 620 , which may include components for storage, conversion and distribution of detected signal 621 as described below. As illustrated, detected signal 621 represents any combination of signals 612 , 613 a, 613 b and 618 . As such, detected signal 621 includes data associated with movements of mill 606 of resection tool 602 and/or tibia 703 within the surgical space monitored by defector 614 .
- Tracking system 619 may be calibrated in order to facilitate or enhance receipt and/or processing of detected signal 621 .
- such calibration is performed by providing signal conversion system 620 with information related to orthopaedic system 600 and the surrounding environment, including the spatial relationship between mill 606 and tool positional marker 610 in resection tool 602 , functional characteristics of mill 606 , the location and/or orientation of markers 609 , and/or dimensional and positional information related to tibia 703 , tissue defect 702 , or other anatomical structures.
- Calibration of tracking system 619 may be accomplished through any suitable system and method, such as by an optically tracked pointer, video or camera imaging, manual information entry, and/or operator performance of specific commands. Where calibration methods are utilized, calibration can be performed regardless of whether tracking system 619 uses active data collection, passive data collection, or a combination of both.
- Signal conversion system 620 includes computer 622 (described above) having processor 624 which has access to data storage device or memory 626 containing conversion software 628 .
- computer 622 is a stand-alone computing device.
- Exemplary stand alone computing devices include a general purpose computer, such as a desktop computer, a laptop computer, and a tablet computer, smartphone, handheld computing device, or other suitable computing devices.
- computer 622 is illustrated as a single computing system, it should be understood that multiple computing systems may be used together, such as over a network or other methods of transferring data.
- computer 622 may be attached to the surgical table rails of a table supporting the patient, so that computer 622 may be both physically small and within the immediate viewing space of the surgeon.
- interaction with a graphical user interlace of computer 622 may be accomplished with a touch screen or mechanical switches which are engaged by the surgeon or a nurse.
- the surgeon or nurse interacts with computer 622 through voice commands received by a microphone associated with the computing system.
- the computing system may be able to identify the voice of the surgeon or other authorized user.
- the surgeon or nurse interacts with the computing system through gestures captured by detector 614 .
- computer 622 or at least a display portion of computer 622 may be contained within a bag or other sterilization mechanism and the surgeon or other authorized user interacts with the computing system through the bag or other sterilization mechanism.
- Memory 626 is a computer readable medium and may be a single storage device or may include multiple storage devices, located either locally with computer 622 or accessible across a network.
- Computer-readable media may be any available media that may be accessed by processor 624 of computer 622 , and includes both volatile and non-volatile media. Further, computer readable-media may be one or both of removable and non-removable media.
- computer-readable media may include, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, Digital Versatile Disk (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which may be used to store the desired information and which may be accessed by computer 622 .
- Computer 622 in addition to containing the specialized instructions for orthopaedic system 600 embodied in conversion software 628 , may also include operating system software (not shown).
- An exemplary operating system software is a WINDOWS operating system available from Microsoft Corporation of Redmond, Wash.
- Computer 622 may further include communications software (not shown) which allows computer 622 to communicate with one or more computer networks, such as a local area network, a wide area network, a public switched network, any type of wired network, any type of wireless network, and combinations thereof.
- An exemplary public switched network is the Internet.
- Exemplary communications software includes browser software, and other types of software which permit computer 622 to communicate with other devices across a network.
- computer 622 also communicates with one or more additional computing devices (not shown) over a network, such as remote computing devices forming part of a hospital network or surgery center network.
- processor 624 of computer 622 receives detected signal 621 and executes instructions of conversion software 628 to convert detected signal 621 into data indicative of the location, orientation, and movement of mill 606 of resection tool 602 . If tibia 703 is also being tracked, comparable data is converted in similar fashion. The converted data is output to memory 626 , where it is stored for further access by conversion software 628 .
- conversion software 628 accesses the stored raw data collected by detector 614 and compiled in memory 626 , and creates a virtual three-dimensional volume from the individual data points.
- This virtual three-dimensional volume represents the same volumetric size, shape and boundaries defined by the data set or “cloud” of data points discussed above.
- Software and systems for removing erroneous and/or outlier data may also be provided to smooth the virtual “surface” of the cloud of data points. Methods for such smoothing include computation of a non-uniform rational B-spline (NURBS) approximation of the virtual surface.
- NURBS non-uniform rational B-spline
- a 3D lowpass filter may be utilized to exclude outliers data points and smooth the virtual surface.
- the virtual volume is translated into a series of implant forming commands 629 , which are instructions (i.e., machine-language instructions) for the manufacture of custom implant 700 by custom implant forming system 630 ( FIG. 1 ). These instructions provide an input to implant forming system 630 to create implant 700 with the same or analogous volumetric characteristics exhibited by the virtual volume, and therefore by void 712 .
- implant forming system 630 is described and shown herein as being a system in the vicinity of orthopaedic system 600 , it is also contemplated that implant forming system may be remote.
- implant forming commands 629 may be transmitted to a remote to an implant forming facility (i.e., via a computer network as discussed above), which may rapidly produce and deliver custom implant 700 to the surgical site.
- Exemplary “made-to-order” systems and methods that may be adapted for use with the present disclosure are disclosed in U.S. Provisional Patent Application Ser. No. 61/324,525, filed Apr. 15, 2010 and entitled METHODS OF ORDERING AN MANUFACTURING ORTHOPEDIC COMPONENTS, which is commonly assigned with the present application, the entire disclosure of which is hereby expressly incorporated by reference herein.
- Memory 626 can continuously aggregate and store data derived from detected signal 621 as such data is received. Such storage allows the user of orthopaedic system 600 to release the aggregated data to conversion software 628 when appropriate, i.e., when the data forms a complete volumetric representation of void 712 after void 712 is completely formed. Thus, implant forming system 630 can begin generation of implant 700 at any time after the final shape and size of void 712 is determined.
- signal conversion system 620 as schematically depicted in FIG. 7 , for example, detected signal 621 is sent directly to a stand-alone memory 626 to be stored as raw data, and is subsequently accessed by conversion software 628 programmed into a stand-alone processor 624 to generate implant forming commands 629 .
- Exemplary stand-alone memory systems include USB storage devices, external CD or DVD drives, and the like.
- signal conversion system 620 includes a stand-alone memory 626 but integrates conversion software 628 into controller 634 of implant forming system 630 . Other permutations of conversion system 620 may be used, as required or desired for a particular application.
- implant forming commands 629 are transmitted from computer 622 to controller 634 via data output cable 605 b.
- Controller 634 separates implant forming commands 629 into cutter commands 637 for implant cutter assembly 638 and implant rotation commands 639 for turntable 640 .
- Controller 634 distributes commands 637 , 639 to their respective hardware destinations via data command transfer cables 637 a, 639 a respectively.
- controller 634 utilizes custom implant forming commands 629 to direct interactions between implant cutter assembly 638 and turntable 640 , which has implant blank 701 (i.e., a standard-sized allograft plug or a synthetic plug) mounted thereto ( FIG. 1 ).
- custom implant forming system 630 manufactures custom implant 700 from implant blank 701 , such that custom implant 700 replicates the volumetric representation of void 712 stored as data points in memory 626 .
- cutter 641 shown as mill 641 a driven by motor 641 b
- robot arm 642 which is capable of moving cutter 641 through multiple degrees of freedom, such as six degrees of freedom.
- a designated portion of implant blank 701 is milled away by cutter 641 according to cutter commands 637 .
- turntable 640 rotates implant blank 701 according to rotation commands 639 , thereby presenting a new portion of implant blank 701 to cutter 641 .
- Cutter 641 then mills away a second designated portion in similar fashion to the first milling operation. This mill-rotate-mill progression is iteratively repeated until all designated portions of implant blank 701 have been removed from the side and/or top of implant blank 701 , leaving finished custom implant 700 .
- implant blank 701 material removal from the bottom face of implant blank 701 may be accomplished by re-mounting implant blank 701 to turntable 640 to present such bottom face to cutter 641 .
- the top and bottom faces of implant blank 701 may be left undisturbed by cutter 641 to fit a void 712 having a particular, preset resection depth D ( FIG. 3 ).
- leaving the top and bottom faces of implant blank 701 undisturbed allows any special finishes on articular surface 700 a and bone-contacting surface 700 b of custom implant 700 to remain intact
- custom implant forming system 630 represents particular embodiment of a computer numerical controlled (CNC) system
- CNC systems may be used, such as laser cutting systems, water jet cutting systems, CNC milling and routing systems, and the like.
- exemplary CNC systems include SINUMERIK brand programmable numeric controllers available from Siemens AG of Berlin, Germany (SINUMERIK is a registered trademark of Siemens AG).
- custom implant 700 may be generated using a rapid prototyping process, such as three dimensional printing, stereolithography, selective laser sintering, fused deposition modeling, laminated object manufacturing, or electron beam melting, for example.
- a rapid prototyping process such as three dimensional printing, stereolithography, selective laser sintering, fused deposition modeling, laminated object manufacturing, or electron beam melting, for example.
- custom implant 700 mimics void 712 created previously by the resection process described above.
- custom implant 700 is illustrated in FIGS. 1 and 2 b as being generally oval in shape, in order to accommodate a correspondingly elongate, oval-shaped resection void 712 ( FIG. 1 ).
- Resection void 712 represents an appropriate resection for the elongate nature of tissue defect 702 ( FIG. 2 a ).
- custom implant 700 may take any shape associated with the movements or functions of mill 606 as represented by the volumetric data conveyed in detected signal 621 .
- orthopaedic system 600 is capable of forming custom implant 700 based on the shape and volumetric characteristics of void 712 , regardless of whether void 712 is irregularly shaped. This allows a surgeon to create void 712 in a freehand manner, thereby allowing the surgeon flexibility in pursuing the surgical goal removal as little of the healthy tissue surrounding defect 702 as practical.
- the freehand resection technique enabled by orthopaedic system 600 is particularly advantageous for elongated or irregular defects such as defect 702 ( FIG. 2 a ).
- Orthopaedic system 600 can be used to create custom implant 700 closely matching the original profile of defect 702 .
- orthopaedic system 600 may monitor the shape of void 712 during resection of defective tissue 702 to avoid an undercut (i.e., a situation in which resection depth D is too small) during a freehand resection.
- the shape and volumetric characteristics of void 712 may be graphically displayed to a surgeon during the resection of defective tissue 702 , including desired resection depth D.
- the display can indicate where further material removal is necessary to avoid and undercut situation. Avoiding an overcut (i.e., a situation in which resection depth D is too large) can be accomplished as described in detail below.
- resection depth D of void 712 may be set to a particular desired value, such as to accommodate custom implant 700 having a given thickness T I while avoiding any resurfacing of articular surface 700 a or bone-contacting surface 700 b (resurfacing of custom implant 700 is described in detail below).
- depth D is greater than thickness T I , such as where defective tissue 702 is found to extend more deeply into tibia 703 than can be accommodated by thickness T I , implant spacers 708 , 709 ( FIG.
- a kit including multiple implant spacers 708 , 709 of varying thickness i.e. thin implant spacer 708 and thick implant spacer 709 , may be provided to offer a wide variety of total implant thicknesses to the surgeon.
- spacers 708 , 709 may be made of a porous bone-ingrowth material.
- signal conversion system 620 may collect data regarding the operational status of resection tool 602 , such as whether resection tool 602 is on or off, how much power is flowing to mill 606 (i.e., the “load state”), etc. This raw data is collected by tool controller 623 ( FIG. 1 ), which in turn transmits signal 643 via data transmission cable 644 to signal computer 622 . It is also contemplated that signal 643 may pass directly from resection tool 602 to computer 622 . Each parcel of data carried by signal 643 may be time-stamped by signal conversion system 620 to correspond with correspondingly time-stamped data regarding the location and orientation of mill 606 , described in detail above.
- Signal conversion system 620 processes signal 643 in a similar fashion to detected signal 621 , which then relays the processed signal back to controller 623 as anatomical shaping commands 625 .
- conversion software 628 iteratively computes the depth of void 712 throughout the resection operation, and compares such computed depth to the pre-defined desired resection depth D (which may be created as part of a pre-surgical plan and stored in memory 626 ).
- signal conversion system 620 issues an appropriate anatomical shaping command 625 to resection tool controller 623 , such as a command to cut power to resection tool 602 or some visual, audio, or tactile indicator, such as an audible alarm. Where power to resection tool 602 is cut in response to anatomical shaping command 625 , signal conversion system 620 may require the operator to provide some form of user feedback to resection tool controller 623 as a condition for restoring power to mill 606 .
- An exemplary system for use in the generation of anatomical shaping commands to control a cutting instrument is described in U.S. Pat. No. 6,757,582, entitled METHODS AND SYSTEMS TO CONTROL A SHAPING TOOL, incorporated by reference above.
- Resection depth D is described above as an exemplary predefined volumetric parameter of void 712 .
- constraining depth D allows surfaces 700 a, 700 b of custom implant 700 to remain undisturbed, thereby keeping any special articular or bone-contacting surface characteristics intact.
- articular surface 700 a may be lubricious and/or smooth to facilitate articulation with an adjacent joint surface (i.e., a femoral condyle), while bone-contacting surface 700 b may be porous or roughened to facilitate bone ingrowth.
- boundaries of other desired volumetric characteristics of void 712 may be established and programmed into controller 623 , and violations of these boundaries may be prevented in the similar fashion as depth D described above.
- Implant 700 may be used with a void 712 having resection depth D that is greater than implant thickness If by utilizing one or more of spacers 708 , 709 as noted above. Implant 700 may be also used with a void 712 having a shallower depth D than implant thickness T I by shaping articular surface 700 a after implantation.
- resection tool 602 may be used to mill an elevated portion of custom implant 700 , such that the finished shape and contour of articular surface 700 a corresponds with the original contour of tissue 704 ( FIG. 1 ), as described in detail below.
- computer 622 may manipulate resection tool 602 via resection tool controller 623 for reasons other than creation of void 712 .
- controller 623 may be ordered to shut down resection tool 602 when mill 606 moves out of the surgical space monitored by detector 614 , or if aberrant power inputs are detected, or after a fixed elapse of time.
- resection tolerances may instead be controlled by the use of cut guides or templates.
- a cut guide (not shown) with a channel may be placed upon tibia 703 over tissue defect 702 , and may physically prevent mill 606 from extending past a particular defined resection depth D (such as by allowing mill 606 to pass through the channel, but not handle 608 ).
- Other cut guide and template arrangements may be used or adapted for use with the present disclosure.
- One exemplary system and method for using a cut guide to control resection depth is disclosed in U.S. Pat. No. 7,794,462, filed Mar. 19, 2007, entitled HANDPIECE CALIBRATION DEVICE, and commonly assigned with the present application, the entire disclosure of which is hereby expressly incorporated by reference.
- surface contour information relating to tissue 704 may be collected prior to excising defective tissue 702 .
- Collection of surface contour information of tissue 704 may be accomplished through any suitable method, including the use of an optically tracked pointer (not shown), video or camera imaging (not shown), and algorithmic extrapolation from information provided by markers 609 ( FIG. 1 ).
- An optically tracked pointer not shown
- video or camera imaging not shown
- algorithmic extrapolation from information provided by markers 609 FIG. 1
- One exemplary embodiment of surface contour collection systems and methods may be found in U.S. patent application Ser. No. 12/191,429, filed Aug.
- custom implant 700 is manufactured by implant forming system 630 to replicate not only the size and shape of void 712 (as described in detail above), but also the original surface contour of tissue 704 .
- conversion software 628 creates custom forming commands 629 from both the acquired data set generated during excision of defective tissue 702 , as well as collected surface contour information.
- Custom implant forming system 630 utilizes custom implant forming commands 629 , which incorporate such surface contour information, to manufacture custom implant 700 to be sized to correspond with the size and shape of void 712 and the contour of tissue 704 .
- orthopaedic system 600 may allow a surgeon to replicate the original surface contour of tissue 704 by “freehand” milling of articular surface 700 a of custom implant 700 after implantation. This method is described in detail below in the context of exemplary surgical methods 650 , 660 .
- method 650 an exemplary method of utilizing orthopaedic system 600 is presented as method 650 .
- the surgeon begins method 650 by accessing defective tissue 702 , using any suitable surgical method including tissue retraction or minimally invasive surgical techniques, at step 20 .
- Step 22 is represented by dashed lines in FIG. 5 to indicate that collection of surface contour information may not be performed, depending on the particular embodiment of orthopaedic system 600 in use and surgeon preference.
- collected surface contour information may be used in conjunction with orthopaedic system 600 to replicate the anatomical surface contour the healthy tissue surrounding defective tissue 702 after implantation of custom implant 700 .
- calibration of tracking system 619 may be performed as described above. While exemplary method 650 depicts calibration of tracking system 619 as occurring after defective tissue 702 is accessed, methods of utilizing orthopaedic system 600 are possible in which any required calibration of signal conversion system 620 may occur prior to accessing defective tissue 702 . Moreover, calibration step 24 is shown in dashed lines to indicate that this step may be eliminated from method 650 as required or desired for a particular application.
- excision step 26 and data acquisition step 28 of exemplary method 650 are performed.
- the surgeon excises tissue defect 702 while contemporaneously acquiring information (such as data associated with movements or functions of mill 606 ) relating to resection tool 602 .
- information such as data associated with movements or functions of mill 606
- data associated with mere movement of resection tool 602 i.e., when mill 606 is not in contact with any portion of tibia 703
- the surgeon may manually provide this data by providing input to orthopaedic system 600 (i.e., via a button or foot pedal) to start and stop data collection.
- the load state of mill 606 may be measured and used to determine when mill 606 is being used to resect tissue.
- resection tool 602 may be calibrated or “taught” the difference between a tissue-resection load state and a free-spinning load state by using resection tool in a controlled environment and correlating collected load state data with the known status (i.e., cutting or not cutting) of mill 606 .
- Yet another option is to collect surface contour information, as described in detail above, arid to register this surface contour information to tibia position marker 609 , so that the outer boundaries of tissue 704 are known within memory 626 of computer 622 . Then, when mill 606 is observed by detector 614 passing this calculated outer bound towards tibia 703 , data points are collected and recorded. Conversely, if mill 606 moved past the outer boundary away from tibia 703 , collection and recordation of data points ceases.
- the acquired data set (at step 28 ) relating to resection tool 602 is stored in memory 626 (step 30 ) of signal conversion system 620 ( FIGS. 1 and 7 - 9 ) and converted at step 32 into implant forming commands 629 by conversion software 628 ( FIGS. 7-9 ).
- implant forming commands 629 are used by custom implant forming system 630 ( FIGS. 1 and 7-9 ) to generate custom implant 700 , as discussed above.
- custom implant 700 is then implanted into void 712 . Because custom implant 700 corresponds in size and shape to void 712 , implant 700 forms a close, custom fit within void 712 . However, a surgeon may perform minor reshaping of implant 700 and/or void 712 to further refine the fit therebetween.
- articular surface 700 a of implant 700 may be milled at step 38 to replicate the original contour of tissue 704 in the manner described above.
- implant resurfacing commands 625 ′ FIG. 1
- implant resurfacing commands 625 ′ may be issued to resection tool controller 623 in a similar manner as anatomical shaping commands 625 , described above.
- implant resurfacing commands 625 ′ are adapted to prevent any shaping of articular surface 700 a beyond the original surface contour of tissue 704 , a virtual model of which was previously generated at step 22 .
- Surface contour information collected prior to excising defective tissue 702 , is first translated by conversion software 628 into a series of surface contour tolerance values and stored in memory 626 .
- computer 622 continuously receives newly detected signals 612 , 613 a, 613 b and 618 (relating to acquired data associated with mill 606 of resection tool 602 , as described above) which is simultaneously and continuously converted to detected signal 621 .
- Detected signal 621 is compared to the previously computed surface contour tolerance values by conversion software 628 . The results of such comparison indicate whether mill 606 of resection tool 602 is nearing a violation of surface contour tolerance values.
- computer 622 provides implant resurfacing command 625 ′ to resection tool controller 623 , which in turn causes shutdown of tissue resection tool 602 and/or some visual, audio, or tactile indicator, such as an audible signal to an operator in a similar fashion as described above.
- resection tool controller 623 causes shutdown of tissue resection tool 602 and/or some visual, audio, or tactile indicator, such as an audible signal to an operator in a similar fashion as described above.
- Method 660 includes the steps of method 650 , but constrains one or more of the boundaries of void 712 to a predefined value (i.e., resection depth D described above) by way of a feedback loop controlling resection tool 602 .
- a predefined value i.e., resection depth D described above
- step 40 is added to define the volumetric characteristics of void 712 .
- implant 700 is generated based on void 712 created during excision step 26 .
- void 712 is itself specified, at least in part, at step 40 . While step 40 is shown as occurring after accessing step 20 , it is contemplated that step 40 can occur at any time before the completion of excision step 26 .
- excision step 26 and data acquisition and storage steps 28 , 30 proceed as described with respect to method 650 ( FIG. 5 ).
- step 30 As the data is stored in step 30 , such data is continuously, iteratively compared in step 42 to the boundaries or outer limits of the desired volumetric characteristics of void 712 defined in step 40 . If the operative end (i.e., mill 606 ) of resection tool 602 is at (or near) this boundary, anatomic shaping command 625 (described in detail above) issues and creates its desired effect, i.e., shutting down resection tool 602 or sounding an alarm. If, on the other hand, the boundary comparison step 42 finds that the operative end of resection tool 602 is within the predefined volume of void 712 , excision step 26 , data acquisition step 28 and data storage step 30 continue.
- the comparison at step 42 is not only performed to compare the acquired data points to the volumetric characteristics of void 712 , but also compares relative position of the data points to defect 702 .
- Registration can be accomplished by any suitable method, such as by touching mill 606 to the center of defect 702 before excision begins, while tibia 703 is tracked or immobilized (as described above). By recording this position of mill 606 within the monitored surgical space, computer 622 is taught the position of defect 702 within the monitored surgical space. Computer 622 can therefore “register” or overlay the desired volumetric characteristics of void 712 with defect 702 , and issue implant forming commands 629 whenever mill 606 is outside of void 712 (and therefore, away from defect 702 ).
- a second inquiry is made at step 46 as to whether void 712 has achieved the desired volumetric characteristics defined in step 40 . If the answer to this inquiry is “yes”, i.e., if the resected volume of void 712 matches the desired volume, then the acquired data set is converted into implant forming commands 629 and the processes of generating, implanting and (optionally) resurfacing custom implant 700 proceeds as described above with respect to method 650 . If, on the other hand, the answer is “no”, i.e., the desired resected volume of void 712 has not yet been achieved, method 660 reverts to excision step 26 to continue removing tissue and expanding void 712 .
- orthopaedic system 600 is described herein in the context of creation and implantation of custom implant 700 , it is contemplated that pre-formed implants may also be used.
- the dimensional representations of void 712 may be compared to a library of predefined shapes for which pre-formed implants are available, i.e., a standard conical shape.
- orthopaedic system 600 may alert the user that a cartilage punch or other standard resection tool corresponding to the predefined shape may be used to create void 712 sized to fit such standard implant.
- resection tool 602 may be controlled by anatomical shaping commands 625 , as described in detail above, to create void 712 corresponding to the shape of a pre-formed implant.
- anatomical shaping commands 625 as described in detail above.
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Abstract
A system and method for repairing an area of defective tissue reduces the removal of healthy tissue at the margins of the defect. During excision of diseased or damaged tissue, the system tracks the movement and function of a tissue resection tool within a monitored surgical space. This movement is continuously recorded to create a three-dimensional set of data points representative of the excised volume of tissue. This data set is then communicated to a custom implant forming device which creates a custom implant sized to fit the void created by the excision. The system and method of the present disclosure allows a surgeon to exercise intraoperative control over the specific shape, volume and geometry of the excised area. Moreover, the surgeon may utilize a “freehand” resection method to excise only that tissue deemed to be diseased and/or damaged, because the custom-formed implant will accommodate an irregularly-shaped resection volume.
Description
- This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 61/308,176, filed Feb. 25, 2010, the entire disclosure of which is hereby expressly incorporated herein by reference.
- 1. Technical Field
- The present disclosure relates to tissue repair and replacement. More particularly, the present disclosure relates to a surgical system for repairing a tissue defect and a method for utilizing the same.
- 2. Description of the Related Art
- Damage to anatomical tissues, i.e. bone and cartilage, may result from trauma, aging or disease, for example. Such damage may result in pain and/or restricted mobility, which in turn may necessitate surgical intervention to repair the damaged tissues. However, some anatomical tissues may require lengthy periods of time to heal or may have limited capability to heal on their own.
- Various techniques have been developed to repair tissue damage, such as procedures for joint arthroplasty procedures in which one or more of the articular surfaces of the joint are replaced. In other cases, where only a portion of a particular articular surface needs replacement, a patch or plug of synthetic cartilage and/or bone is implanted in a void created by excision of the damaged tissue. Still other methods, such as mosaicpiasty and osteochondral autograft transfer, harvest viable natural cartilage from one area of the body and implant it at the site of the excised damaged tissue.
- Where a small area of tissue is removed to repair a defect or injury affecting only a portion of an articular surface, one potential method is to remove a cylinder of tissue large enough to encompass the defect, and then implant a pre-made prosthetic plug sized to fit the cylindrical void created by the resection. However, use of this method for elongate defects, such as hairline fractures or irregularly shaped diseased tissue profiles, may result in the removal of a large proportion of healthy tissue material In order to reduce the removal of healthy tissue, smaller cylindrical excisions can be serially arranged along the extent of an elongate defect, and smaller cylindrical plugs can then be placed in a line along the resected area.
- The present disclosure provides a system and method for repairing an area of defective tissue which reduces the removal of healthy tissue at the margins of the defect. During excision of diseased or damaged tissue, the system tracks the movement and function of a tissue resection tool within a monitored surgical space. This movement is continuously recorded to create a three-dimensional set of data points representative of the excised volume of tissue. This data set is then communicated to a custom implant forming device which creates a custom implant sized to fit the void created by the excision. The system and method of the present disclosure allows a surgeon to exercise intraoperative control over the specific shape, volume and geometry of the excised area. Moreover, the surgeon may utilize a “freehand” resection method to excise only that tissue deemed to be diseased and/or damaged, because the custom-formed implant will accommodate an irregularly-shaped resection volume.
- According to one embodiment thereof, the present disclosure provides a system for repairing a tissue defect, the system comprising: a resection tool having an operative end adapted to resect anatomical tissue; at least one positional marker in a known spatial relationship to the resection tool, the at least one positional marker forming an emanated signal indicative of at least one of a position and an orientation of the operative end of the resection tool, such that movement of the resection tool creates a plurality of data points representative of a volume; a controller communicatively connected to the at least one positional marker and operable to receive the emanated signal, the controller including software adapted to translate the emanated signal into implant forming commands; and an implant forming system which utilizes the implant forming commands to form a custom implant sized to replicate the volume represented by the plurality of data points.
- In one aspect thereof, the system provides a detector monitoring a surgical space, the detector operable to detect the emanated signal within the monitored surgical space, wherein the at least one positional marker generates the emanated signal. In another aspect, the system provides a detector monitoring a surgical space, the detector operable to detect the emanated signal within the monitored surgical space; and a signal generator producing an ambient signal within the monitored surgical space, wherein the at least one positional marker reflects at least a portion of the ambient signal to create the emanated signal.
- According to another embodiment thereof, the present disclosure provides a method of repairing a tissue defect in an anatomical structure, the method comprising the steps of removing a portion of the anatomical structure to create a void having a first shape, the portion including the tissue defect; determining a second shape corresponding to the first shape of the void; and after the step of determining a second shape, manufacturing an implant having the second shape for placement within the void, the second shape generally matching the first shape.
- According to yet another embodiment thereof, the present disclosure provides a method system for repairing a tissue defect within a monitored surgical space, the system comprising: means for resecting tissue to create a void having a void size and void shape, the means for resecting comprising: an operative end; and a positional marker in a known spatial relationship to the operative end; means for detecting movement of the positional marker within the monitored surgical space, the means for detecting movement producing a signal; means for converting the signal into implant forming commands; and means for using the implant forming commands to form a custom implant, wherein the custom implant has an implant size corresponding to the void size and an implant shape corresponding to the void shape.
- The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will be better understood by reference to the following descriptions of embodiments of the disclosure taken in conjunction with the accompanying drawings, wherein:
-
FIG. 1 is a perspective view of an embodiment of an orthopaedic system in accordance with the present disclosure, illustrating a custom implant formed to ill an irregularly shaped void; -
FIG. 2a is a perspective view of a proximal portion of a tibia, in which the tibial articular surface has an elongate tissue defect; -
FIG. 2b is a partial perspective view of the proximal tibia shownFIG. 2 a, illustrating an irregularly-shaped implant filling a correspondingly shaped void after excision of the tissue defect shown inFIG. 2 a; -
FIG. 3 is an elevation, section view of the proximal tibia shown inFIG. 2 a, illustrating a custom implant and optional shims; -
FIG. 4a is a perspective view of a cutting instrument in accordance with the present disclosure; -
FIG. 4b is a perspective view of another cutting instrument in accordance with the present disclosure; -
FIG. 5 is a flow chart of an exemplary method of the present disclosure; -
FIG. 6 is a flow chart of another exemplary method of the present disclosure; -
FIG. 7 is a schematic view of an exemplary tracked cartilage repair system in accordance with the present disclosure; -
FIG. 8 is a is a schematic view of another exemplary tracked cartilage repair system in accordance with the present disclosure; and -
FIG. 9 is a schematic view of yet another exemplary tracked cartilage repair system in accordance with the present disclosure. - Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the disclosure and such exemplifications are not to be construed as limiting the scope of the disclosure in any manner.
- Referring to
FIG. 1 ,orthopaedic system 600 includes trackedtissue resection tool 602,tracking system 619,signal conversion system 620, and customimplant forming system 630. Asresection tool 602 is used to resect defective tissue 702 (FIG. 2a ),tracking system 619 monitors the movement oftool 602. Data points indicative of the monitored cutter position are collected throughout the resection, rendering a set or “cloud” of data points bounding a virtual volume that is representative ofvoid 712.Tracking system 619 sends this data set tosignal conversion system 620, which in turn converts the data intoimplant forming commands 629.Implant forming commands 629 are then sent to implant formingsystem 630, which createscustom implant 700 sized and shaped to fillvoid 712 created by the resection ofdefective tissue 702. - In the illustrated embodiment,
orthopaedic system 600 is used to repair defect 702 (FIG. 2a ) located intissue 704 at the proximal end oftibia 703. However, it is contemplated thatorthopaedic system 600 may be used to repair other types of tissue, such as bone and non-articular forms of cartilage (such as elastic and fibro cartilage), and may be used for other anatomical surfaces, including but not limited to surfaces associated with the femur, distal tibia, pelvis, talus, glenoid, or humerus, for example. - Referring still to
FIG. 1 ,tissue resection tool 602 includes an operative end adapted to resect tissue, shown asmill 606.Mill 606 is rotatably driven by power transmitted from a remote power source (i.e., an electrical outlet or compressed air reservoir, not shown) viapower transmission cable 605. Trigger 603 controls the delivery of power tomill 606.Resection tool 602 can be said to be a “freehand” cutting tool, in that an operator can hold andmaneuver handle 608 while manipulatingtrigger 603 to selectively resect defective tissue 702 (FIG. 2a ) in a freehand manner, as described in detail below. An exemplary cutting instrument suitable for use with the present system is described in U.S. Pat. No. 6,757,582, entitled METHODS AND SYSTEMS TO CONTROL A SHAPING TOOL, the entire disclosure of which is hereby expressly incorporated herein by reference. - Referring to
FIGS. 4a and 4 b,tissue resection tools 602 a, 602 b, are hand-held instruments similar totissue resection tool 602, but have alternative operative ends.Tissue resection tool 602 a ofFIG. 4a includes oscillating blade 606 a, while resection tool 602 b ofFIG. 4b includes scalpel 606 b. Moreover, it is contemplated that the operative end ofresection tool 602 may be any cutting tool or device capable of excising a quantity of tissue from an anatomical surface, such as a retractable blade, a particulate stream, a cautery device, a rotary cutting blade, a cartilage punch, or an ultrasonic cutting device, for example, - In an exemplary embodiment,
tissue resection tool 602 may be modularly adaptable for use with any number of different operative ends. As noted below, an operative end (such as mill 606) ofresection tool 602 is in a known spatial relationship with toolpositional marker 610, which allows the spatial position and orientation of the operative end to be monitored. When an alternative operative end having a differing geometry replacesmill 606,orthopaedic system 600 is adjusted to account for this new geometry. To effect such adjustment, the user may input identifying information for the new operative end intocomputer 622, such as by selecting from a pre-programmed list of known operative ends (i.e., “mill,” “oscillating blade” or “scalpel”). Specific geometrical and spatial geometry information for each operative end is programmed intocomputer 622, which in turn allowsorthopaedic system 600 to account for any spatial differences between toolpositional marker 610 and respective operative ends (i.e., operative ends 606, 606 a, 606 b). In another example, operative ends 606, 606 a, 606 b may each include a unique identifier readable byresection tool 602, such as a barcode, radio frequency identification (RFID) tag, or magnet. When one of operative ends 606, 606 a, 606 b is installed ontoresection tool 602, this identifier is sent tocomputer 622 automatically (i.e., via wireless transmission), obviating the need for the system user to input the information manually. - Although
tissue resection tools resection tool 602 are also contemplated. For example, computer-controlled or haptic robotic arms may be used in conjunction with the present system, such as the system described in U.S. patent application Ser. No. 11/610,728, filed Dec. 14, 2006, entitled IMAGELESS ROBOTIZED DEVICE AND METHOD FOR SURGICAL TOOL GUIDANCE, and commonly assigned with the present application, the entire disclosure of which is hereby expressly incorporated herein by reference. - Referring again to
FIG. 1 ,orthopaedic system 600 further includestracking system 619 for monitoring the position, orientation and movement ofresection tool 602 within a tracked surgical space. In an exemplary embodiment,tracking system 619 includes one or more resection toolpositional markers 610 anddetector 614, which cooperate to generate data indicative of the position and orientation ofmill 606 within a field of view ofdetector 614, as described below. Although asingle detector 614 is shown inFIG. 1 for simplicity, it is contemplated that multiple-detector systems may be used to monitor the surgical space. - Turning now to
FIG. 7 , an embodiment oftracking system 619 which monitors the position and orientation ofresection tool 602 is schematically depicted. Resection toolpositional marker 610 is coupled toresection tool 602, such that the position ofmill 606 is in a known (i.e., fixed or calculable) spatial relationship withmarker 610. During excision of a target volume, such as the material surrounding and including tissue defect 702 (FIG. 2a ),detector 614 receives signals 612 emanating frompositional marker 610, and each received signal 612 provides a discrete parcel of data indicative of the position and orientation ofmill 606. One exemplary detector suitable for use with the present system is the POLARIS SPECTRA brand optical tracking system, which is produced by Northern Digital Inc., of Ontario, Canada (POLARIS SPECTRA is a registered trademark of Northern Digital Inc.). Becausepositional marker 610 internally generates and distributes signal 612 todetector 614,tracking system 619 may be said to use an active data collection modality. Examples of internally generated signals 612 suitable for use withorthopaedic system 600 include visible light (e.g., light emitting diodes), fluoroscopic, infrared, radio frequency, electromagnetic, or ultrasonic forms of signals, and the like. In exemplary embodiments, internally generated signals may come from accelerometers, gyroscope-based sensors, inclinometers, and other signal generation devices described in U.S. patent application Ser. No. 12/410,884, filed Mar. 25, 2009 and entitled METHOD AND SYSTEM FOR PLANNING/GUIDING ALTERATIONS TO A BONE, and in U.S. patent application Ser. No. 12/410,854, filed Mar. 25, 2009 and entitled TRACKING SYSTEM AND METHOD, the entire disclosures of which are hereby incorporated herein by reference. - When using
tracking system 619 as depicted inFIG. 7 , movements ofresection tool 602 are monitored bydetector 614, and recordation of such movements generates a set of data points representative of a volume of resected material. The data points, which are clustered together within a virtual volume, can be said for form a “cloud” of data points as noted above. At the beginning of resection ofdefective tissue 702, a first data point collected at a first three-dimensional coordinate can be said to represent a starting point ofresection tool 602. Asdefective tissue 702 is resected to createvoid 712, subsequent data points collected at subsequent three-dimensional coordinates can be said to represent a corresponding movement ofresection tool 602. As a multitude of data points is collected, the data points will combine to define a three-dimensional volume which contains or is tangent to every collected data point This three-dimensional volume defined by the “cloud” of data points has a shape and size that mimics the three-dimensional volume ofvoid 712. As described below, this set or cloud of data points is subsequently used to createcustom implant 700 such thatimplant 700 is sized and shaped to correspond to void 712. - In addition to
positional marker 610 fixed toresection tool 602,tracking system 619 may include tibia position markers 609 (FIG. 1 ) fixed totibia 703. Referring toFIG. 8 , an embodiment of theorthopaedic system 600 in whichtracking system 619 monitors the positions of bothtibia 703 andresection tool 602 is schematically illustrated. As described in detail below, the addition of tibial position monitoring allows movement oftibia 703 during the surgical procedure while preserving the ability to collect comprehensive and accurate data regarding the volumetric characteristics of void 712 (FIG. 1 ) formed during resection of defective tissue 702 (FIG. 2a ). - As described above with respect: to the configuration of
tracking system 619 shown inFIG. 7 , a set or cloud of data points is created during resection ofdefective tissue 702. However, iftibia 703 moves during this resection,defective tissue 702 andresection tool 602 move also. If such movement is not accounted for, the three-dimensional coordinates of a data point collected before the movement will fail to properly correspond with the three-dimensional coordinates of a data point collected after the movement because the latter data point will be spaced from the former data point not only by the amount of movement ofresection tool 602, but also by the amount of movement oftibia 703. Tracking the movement oftibia 703, on the other hand, allows the vector associated with a given movement oftibia 703 at a given time to be subtracted from the vector associated with the movement ofresection tool 602 at the same time, thereby correcting for tibial movement and keeping the integrity of the data cloud intact. - In the illustrative embodiment of
FIG. 2 a,tibia position marker 609 includes an array offiducials 609 a, which are collectively fixed totibia 703 in a known (i.e., fixed or calculable) spatial relationship withtissue defect 702. External signal generator 613 (FIG. 8 ) generates controller ambient signal 613 a in the tracked surgical space, and fiducials 609 a reflect ambient signal 613 a to produce reflected signal 613 b. As shown inFIG. 2 a,position marker 609 includes fourfiducials 609 a arranged in a generally planar configuration. The individual point signals emanating from each of the fourfiducials 609 a define a planar quadrilateral shape, the position and orientation of which can be determined within the tracked surgical space. By contrast, a single point signal can show movement but not changes in orientation. Thus, reflected signal 613 b emanating frompositional marker 609 is indicative of the position and orientation of tibia 703 (and, thus, of tissue defect 702). Movement oftibia 703 is monitored bydetector 614 in a similar manner as discussed above with respect to the monitored movement ofresection tool 602. - Because emanation of signal 613 b from tibia
positional marker 609 is accomplished by passively reflecting the externally generated ambient signal 613 a,tracking system 619 as depicted inFIG. 8 may be said to use a passive data collection modality in addition to the active data collection described above. Externally generated, ambient signal 613 a can be any signal capable of creating a reflected signal 613 b that is uniquely distinguishable from ambient signal 613 a bydetector 614. For example, ambient signal 613 a may be altered to produce reflected signal 613 b by a change in frequency, wavelength, or shape of ambient signal 613 a, or by redirection of less than all of ambient signal 613 a. Exemplary systems and methods for passive data collection are described in U.S. patent application Ser. Nos. 12/410,854 and 12/410,884, incorporated by reference above. - It is contemplated that positional tracking and the associated acquisition of data for one or both of
tibia 703 andresection tool 602 may be accomplished using any combination of active data collection and passive data collection. For example,FIG. 9 schematically illustratesorthopaedic system 600 havingtracking system 619′, which utilizes only passive data collection for collection of data indicative of the position and orientation ofmill 606 ofresection tool 602. In the depicted embodiment,tracking system 619′ includes signal generator 616 which generates ambient signal 617, and further includes passive tool position marker 615 which is coupled toresection tool 602 in a known (i.e., fixed or calculable) spatial relationship tomill 606. Passive tool position marker 615 is generally analogous totibia position marker 609, which includes an array offiducials 609 a as described above. However, passive tool position marker 615 is fixed toresection tool 602 rather thantibia 703. Upon interacting with passive tool position marker 615, ambient signal 617 is altered and transmitted todetector 614 as reflected signal 618. Signal generator 616, ambient signal 617 and reflected signal 618 are generally analogous to generator 613, ambient signal 613 a and reflected signal 613 b, discussed above, except for being adapted for use withresection tool 602 rather thantibia 703. - Other embodiments of tracking
system 619 are contemplated, including systems utilizing any combination of active and passive data collection for acquiring data associated withmill 606 ofresection tool 602 and/ortibia 703. For example, a “fully passive” system may include a combination of passive marker 609 (FIGS. 1, 2 a and 8) affixed totibia 703, passive tool position marker 615 (FIG. 9 ) coupled toresection tool 602, and one or both of signal generators 613, 616 (FIGS. 8 and 9 ).Passive markers 609, 615 may reflect one or more ambient signals (i.e., signals 613 a, 617) to create distinct reflected signals 613 b, 618 that are distinguishable from one another bydetector 614, or by separate individual detectors. -
Detector 614 thus receives any number of reflected or generated signals from the monitored surgical space, as described above. Turning again toFIG. 1 , these aggregated received signals pass fromdetector 614 tocomputer 622 via data input cable 605 a as detected signal 621 (FIGS. 7-9 ). Detectedsignal 621 is received bysignal conversion system 620, which may include components for storage, conversion and distribution of detectedsignal 621 as described below. As illustrated, detectedsignal 621 represents any combination of signals 612, 613 a, 613 b and 618. As such, detectedsignal 621 includes data associated with movements ofmill 606 ofresection tool 602 and/ortibia 703 within the surgical space monitored bydefector 614. -
Tracking system 619 may be calibrated in order to facilitate or enhance receipt and/or processing of detectedsignal 621. In one exemplary embodiment, such calibration is performed by providingsignal conversion system 620 with information related toorthopaedic system 600 and the surrounding environment, including the spatial relationship betweenmill 606 and toolpositional marker 610 inresection tool 602, functional characteristics ofmill 606, the location and/or orientation ofmarkers 609, and/or dimensional and positional information related totibia 703,tissue defect 702, or other anatomical structures. Calibration oftracking system 619 may be accomplished through any suitable system and method, such as by an optically tracked pointer, video or camera imaging, manual information entry, and/or operator performance of specific commands. Where calibration methods are utilized, calibration can be performed regardless of whether trackingsystem 619 uses active data collection, passive data collection, or a combination of both. - Referring now to
FIG. 8 , an exemplary embodiment ofsignal conversion system 620 is shown schematically.Signal conversion system 620 includes computer 622 (described above) havingprocessor 624 which has access to data storage device ormemory 626 containingconversion software 628. In the exemplary embodiment ofFIG. 1 ,computer 622 is a stand-alone computing device. Exemplary stand alone computing devices include a general purpose computer, such as a desktop computer, a laptop computer, and a tablet computer, smartphone, handheld computing device, or other suitable computing devices. Althoughcomputer 622 is illustrated as a single computing system, it should be understood that multiple computing systems may be used together, such as over a network or other methods of transferring data. - In one embodiment,
computer 622 may be attached to the surgical table rails of a table supporting the patient, so thatcomputer 622 may be both physically small and within the immediate viewing space of the surgeon. Whencomputer 622 is within the surgeon's grasp, interaction with a graphical user interlace ofcomputer 622 may be accomplished with a touch screen or mechanical switches which are engaged by the surgeon or a nurse. In one embodiment, the surgeon or nurse interacts withcomputer 622 through voice commands received by a microphone associated with the computing system. The computing system may be able to identify the voice of the surgeon or other authorized user. In one embodiment, the surgeon or nurse interacts with the computing system through gestures captured bydetector 614. In any of the discussed embodiments,computer 622 or at least a display portion ofcomputer 622 may be contained within a bag or other sterilization mechanism and the surgeon or other authorized user interacts with the computing system through the bag or other sterilization mechanism. -
Memory 626 is a computer readable medium and may be a single storage device or may include multiple storage devices, located either locally withcomputer 622 or accessible across a network. Computer-readable media may be any available media that may be accessed byprocessor 624 ofcomputer 622, and includes both volatile and non-volatile media. Further, computer readable-media may be one or both of removable and non-removable media. By way of example, computer-readable media may include, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, Digital Versatile Disk (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which may be used to store the desired information and which may be accessed bycomputer 622. -
Computer 622, in addition to containing the specialized instructions fororthopaedic system 600 embodied inconversion software 628, may also include operating system software (not shown). An exemplary operating system software is a WINDOWS operating system available from Microsoft Corporation of Redmond, Wash.Computer 622 may further include communications software (not shown) which allowscomputer 622 to communicate with one or more computer networks, such as a local area network, a wide area network, a public switched network, any type of wired network, any type of wireless network, and combinations thereof. An exemplary public switched network is the Internet. Exemplary communications software includes browser software, and other types of software which permitcomputer 622 to communicate with other devices across a network. In one embodiment,computer 622 also communicates with one or more additional computing devices (not shown) over a network, such as remote computing devices forming part of a hospital network or surgery center network. - In use, and as illustrated in
FIG. 8 ,processor 624 ofcomputer 622 receives detectedsignal 621 and executes instructions ofconversion software 628 to convert detectedsignal 621 into data indicative of the location, orientation, and movement ofmill 606 ofresection tool 602. Iftibia 703 is also being tracked, comparable data is converted in similar fashion. The converted data is output tomemory 626, where it is stored for further access byconversion software 628. - When executed by
processor 624,conversion software 628 accesses the stored raw data collected bydetector 614 and compiled inmemory 626, and creates a virtual three-dimensional volume from the individual data points. This virtual three-dimensional volume represents the same volumetric size, shape and boundaries defined by the data set or “cloud” of data points discussed above. Software and systems for removing erroneous and/or outlier data may also be provided to smooth the virtual “surface” of the cloud of data points. Methods for such smoothing include computation of a non-uniform rational B-spline (NURBS) approximation of the virtual surface. Alternatively, a 3D lowpass filter may be utilized to exclude outliers data points and smooth the virtual surface. - The virtual volume is translated into a series of
implant forming commands 629, which are instructions (i.e., machine-language instructions) for the manufacture ofcustom implant 700 by custom implant forming system 630 (FIG. 1 ). These instructions provide an input to implant formingsystem 630 to createimplant 700 with the same or analogous volumetric characteristics exhibited by the virtual volume, and therefore byvoid 712. - Although
implant forming system 630 is described and shown herein as being a system in the vicinity oforthopaedic system 600, it is also contemplated that implant forming system may be remote. For example,implant forming commands 629 may be transmitted to a remote to an implant forming facility (i.e., via a computer network as discussed above), which may rapidly produce and delivercustom implant 700 to the surgical site. Exemplary “made-to-order” systems and methods that may be adapted for use with the present disclosure are disclosed in U.S. Provisional Patent Application Ser. No. 61/324,525, filed Apr. 15, 2010 and entitled METHODS OF ORDERING AN MANUFACTURING ORTHOPEDIC COMPONENTS, which is commonly assigned with the present application, the entire disclosure of which is hereby expressly incorporated by reference herein. -
Memory 626 can continuously aggregate and store data derived from detectedsignal 621 as such data is received. Such storage allows the user oforthopaedic system 600 to release the aggregated data toconversion software 628 when appropriate, i.e., when the data forms a complete volumetric representation ofvoid 712 aftervoid 712 is completely formed. Thus, implant formingsystem 630 can begin generation ofimplant 700 at any time after the final shape and size ofvoid 712 is determined. - It is also contemplated that the multiple functions performed by
computer 622 may be performed by stand-alone components, or these functions may be integrated into other parts oforthopaedic system 600. Referring to signalconversion system 620 as schematically depicted inFIG. 7 , for example, detectedsignal 621 is sent directly to a stand-alone memory 626 to be stored as raw data, and is subsequently accessed byconversion software 628 programmed into a stand-alone processor 624 to generate implant forming commands 629. Exemplary stand-alone memory systems include USB storage devices, external CD or DVD drives, and the like. In the configuration shown inFIG. 9 signal conversion system 620 includes a stand-alone memory 626 but integratesconversion software 628 intocontroller 634 ofimplant forming system 630. Other permutations ofconversion system 620 may be used, as required or desired for a particular application. - In the embodiment of
FIG. 1 ,implant forming commands 629 are transmitted fromcomputer 622 tocontroller 634 viadata output cable 605 b.Controller 634 separates implant formingcommands 629 into cutter commands 637 forimplant cutter assembly 638 and implant rotation commands 639 forturntable 640.Controller 634 distributescommands 637, 639 to their respective hardware destinations via datacommand transfer cables 637 a, 639 a respectively. In this way,controller 634 utilizes customimplant forming commands 629 to direct interactions betweenimplant cutter assembly 638 andturntable 640, which has implant blank 701 (i.e., a standard-sized allograft plug or a synthetic plug) mounted thereto (FIG. 1 ). - Under such directed interaction between
implant cutter assembly 638 and implant blank 701, customimplant forming system 630 manufacturescustom implant 700 from implant blank 701, such thatcustom implant 700 replicates the volumetric representation ofvoid 712 stored as data points inmemory 626. With implant blank 701 fixed toturntable 640, cutter 641 (shown as mill 641 a driven by motor 641 b) advances toward blank 701 by articulation ofrobot arm 642, which is capable of movingcutter 641 through multiple degrees of freedom, such as six degrees of freedom. A designated portion of implant blank 701 is milled away bycutter 641 according to cutter commands 637. When such designated portion of the material of implant blank 701 has been fully removed,turntable 640 rotates implant blank 701 according to rotation commands 639, thereby presenting a new portion of implant blank 701 tocutter 641.Cutter 641 then mills away a second designated portion in similar fashion to the first milling operation. This mill-rotate-mill progression is iteratively repeated until all designated portions of implant blank 701 have been removed from the side and/or top of implant blank 701, leavingfinished custom implant 700. - It is also contemplated that material removal from the bottom face of implant blank 701 may be accomplished by re-mounting implant blank 701 to
turntable 640 to present such bottom face tocutter 641. In an exemplary embodiment, however, the top and bottom faces of implant blank 701 may be left undisturbed bycutter 641 to fit a void 712 having a particular, preset resection depth D (FIG. 3 ). As noted below, leaving the top and bottom faces of implant blank 701 undisturbed allows any special finishes on articular surface 700 a and bone-contacting surface 700 b ofcustom implant 700 to remain intact - While custom
implant forming system 630 represents particular embodiment of a computer numerical controlled (CNC) system, other CNC systems may be used, such as laser cutting systems, water jet cutting systems, CNC milling and routing systems, and the like. Examples of exemplary CNC systems include SINUMERIK brand programmable numeric controllers available from Siemens AG of Berlin, Germany (SINUMERIK is a registered trademark of Siemens AG). - However, it is also contemplated that any number of other suitable methods may be used to create
custom implant 700 from a raw or blank material, such thatimplant 700 replicates the resected volume ofvoid 712. For example,custom implant 700 may be generated using a rapid prototyping process, such as three dimensional printing, stereolithography, selective laser sintering, fused deposition modeling, laminated object manufacturing, or electron beam melting, for example. - Once created, the shape and profile of
implant 700 mimics void 712 created previously by the resection process described above. For example,custom implant 700 is illustrated inFIGS. 1 and 2 b as being generally oval in shape, in order to accommodate a correspondingly elongate, oval-shaped resection void 712 (FIG. 1 ).Resection void 712 represents an appropriate resection for the elongate nature of tissue defect 702 (FIG. 2a ). However,custom implant 700 may take any shape associated with the movements or functions ofmill 606 as represented by the volumetric data conveyed in detectedsignal 621. - As it is described above,
orthopaedic system 600 is capable of formingcustom implant 700 based on the shape and volumetric characteristics ofvoid 712, regardless of whethervoid 712 is irregularly shaped. This allows a surgeon to create void 712 in a freehand manner, thereby allowing the surgeon flexibility in pursuing the surgical goal removal as little of the healthytissue surrounding defect 702 as practical. The freehand resection technique enabled byorthopaedic system 600 is particularly advantageous for elongated or irregular defects such as defect 702 (FIG. 2a ).Orthopaedic system 600 can be used to createcustom implant 700 closely matching the original profile ofdefect 702. By contrast, making acylindrical resection 800 to fit a pre-made cylindrical plug can result in removal of a larger proportion of healthy tissue, as illustrated inFIG. 2 b. In addition, the freehand technique may reduce the surgical time requirements, asorthopaedic system 600 obviates the need for multiple standard-size plugs used in some mosaicplasty systems and methods. In addition,orthopaedic system 600 may monitor the shape ofvoid 712 during resection ofdefective tissue 702 to avoid an undercut (i.e., a situation in which resection depth D is too small) during a freehand resection. In one exemplary embodiment, the shape and volumetric characteristics ofvoid 712 may be graphically displayed to a surgeon during the resection ofdefective tissue 702, including desired resection depth D. The display can indicate where further material removal is necessary to avoid and undercut situation. Avoiding an overcut (i.e., a situation in which resection depth D is too large) can be accomplished as described in detail below. - However, it is contemplated that some constraints may be placed on the otherwise freehand resection method for creating
void 712. Referring toFIG. 3 , for example, resection depth D ofvoid 712 may be set to a particular desired value, such as to accommodatecustom implant 700 having a given thickness TI while avoiding any resurfacing of articular surface 700 a or bone-contacting surface 700 b (resurfacing ofcustom implant 700 is described in detail below). Where depth D is greater than thickness TI, such as wheredefective tissue 702 is found to extend more deeply intotibia 703 than can be accommodated by thickness TI, implant spacers 708, 709 (FIG. 3 ) may be disposed between bone-contacting surface 700 b ofimplant 700 and the lower resected surface 712 a ofvoid 712 to bring articular surface to a desired elevation. As illustrated inFIG. 3 , a kit includingmultiple implant spacers 708, 709 of varying thickness, i.e. thin implant spacer 708 andthick implant spacer 709, may be provided to offer a wide variety of total implant thicknesses to the surgeon. In an exemplary embodiment,spacers 708, 709 may be made of a porous bone-ingrowth material. - In order to facilitate the use of
resection tool 602 for the creation ofvoid 712 having a particular, predefined depth D,signal conversion system 620 may collect data regarding the operational status ofresection tool 602, such as whetherresection tool 602 is on or off, how much power is flowing to mill 606 (i.e., the “load state”), etc. This raw data is collected by tool controller 623 (FIG. 1 ), which in turn transmits signal 643 via data transmission cable 644 to signalcomputer 622. It is also contemplated thatsignal 643 may pass directly fromresection tool 602 tocomputer 622. Each parcel of data carried bysignal 643 may be time-stamped bysignal conversion system 620 to correspond with correspondingly time-stamped data regarding the location and orientation ofmill 606, described in detail above. -
Signal conversion system 620 processes signal 643 in a similar fashion to detectedsignal 621, which then relays the processed signal back tocontroller 623 as anatomical shaping commands 625. In an exemplary embodiment,conversion software 628 iteratively computes the depth ofvoid 712 throughout the resection operation, and compares such computed depth to the pre-defined desired resection depth D (which may be created as part of a pre-surgical plan and stored in memory 626). If comparison of detectedsignal 621 indicatesmill 606 ofresection tool 602 is at or near a position that violates the pre-defined resection depth D, then signalconversion system 620 issues an appropriate anatomical shaping command 625 toresection tool controller 623, such as a command to cut power toresection tool 602 or some visual, audio, or tactile indicator, such as an audible alarm. Where power toresection tool 602 is cut in response to anatomical shaping command 625,signal conversion system 620 may require the operator to provide some form of user feedback toresection tool controller 623 as a condition for restoring power tomill 606. An exemplary system for use in the generation of anatomical shaping commands to control a cutting instrument is described in U.S. Pat. No. 6,757,582, entitled METHODS AND SYSTEMS TO CONTROL A SHAPING TOOL, incorporated by reference above. - Resection depth D is described above as an exemplary predefined volumetric parameter of
void 712. Advantageously, constraining depth D allows surfaces 700 a, 700 b ofcustom implant 700 to remain undisturbed, thereby keeping any special articular or bone-contacting surface characteristics intact. For example, articular surface 700 a may be lubricious and/or smooth to facilitate articulation with an adjacent joint surface (i.e., a femoral condyle), while bone-contacting surface 700 b may be porous or roughened to facilitate bone ingrowth. However, it is contemplated that boundaries of other desired volumetric characteristics ofvoid 712 may be established and programmed intocontroller 623, and violations of these boundaries may be prevented in the similar fashion as depth D described above. -
Implant 700 may be used with a void 712 having resection depth D that is greater than implant thickness If by utilizing one or more ofspacers 708, 709 as noted above.Implant 700 may be also used with a void 712 having a shallower depth D than implant thickness TI by shaping articular surface 700 a after implantation. For example,resection tool 602 may be used to mill an elevated portion ofcustom implant 700, such that the finished shape and contour of articular surface 700 a corresponds with the original contour of tissue 704 (FIG. 1 ), as described in detail below. - In addition to generating anatomical shaping commands 625 as described above,
computer 622 may manipulateresection tool 602 viaresection tool controller 623 for reasons other than creation ofvoid 712. For example,controller 623 may be ordered to shut downresection tool 602 whenmill 606 moves out of the surgical space monitored bydetector 614, or if aberrant power inputs are detected, or after a fixed elapse of time. - As an alternative to controlling resection tolerances via
orthopaedic system 600, as described above, resection tolerances may instead be controlled by the use of cut guides or templates. For example, a cut guide (not shown) with a channel may be placed upontibia 703 overtissue defect 702, and may physically preventmill 606 from extending past a particular defined resection depth D (such as by allowingmill 606 to pass through the channel, but not handle 608). Other cut guide and template arrangements may be used or adapted for use with the present disclosure. One exemplary system and method for using a cut guide to control resection depth is disclosed in U.S. Pat. No. 7,794,462, filed Mar. 19, 2007, entitled HANDPIECE CALIBRATION DEVICE, and commonly assigned with the present application, the entire disclosure of which is hereby expressly incorporated by reference. - In addition to collecting data associated with the movements and/or functions of
resection tool 602, surface contour information relating to tissue 704 (FIG. 1 ), which surrounds and includesdefective tissue 702, may be collected prior to excisingdefective tissue 702. Collection of surface contour information oftissue 704 may be accomplished through any suitable method, including the use of an optically tracked pointer (not shown), video or camera imaging (not shown), and algorithmic extrapolation from information provided by markers 609 (FIG. 1 ). One exemplary embodiment of surface contour collection systems and methods may be found in U.S. patent application Ser. No. 12/191,429, filed Aug. 14, 2008, entitled METHOD OF DETERMINING A CONTOUR OF AN ANATOMICAL STRUCTURE AND SELECTING AN ORTHOPAEDIC IMPLANT TO REPLICATE THE ANATOMICAL STRUCTURE, and commonly assigned with the present application, the entirety of which is hereby expressly incorporated herein by reference. - According to one embodiment of
orthopaedic system 600,custom implant 700 is manufactured byimplant forming system 630 to replicate not only the size and shape of void 712 (as described in detail above), but also the original surface contour oftissue 704. In this embodiment,conversion software 628 createscustom forming commands 629 from both the acquired data set generated during excision ofdefective tissue 702, as well as collected surface contour information. Customimplant forming system 630 utilizes customimplant forming commands 629, which incorporate such surface contour information, to manufacturecustom implant 700 to be sized to correspond with the size and shape ofvoid 712 and the contour oftissue 704. - In yet another configuration,
orthopaedic system 600 may allow a surgeon to replicate the original surface contour oftissue 704 by “freehand” milling of articular surface 700 a ofcustom implant 700 after implantation. This method is described in detail below in the context of exemplarysurgical methods 650, 660. - Referring now to
FIG. 5 , an exemplary method of utilizingorthopaedic system 600 is presented asmethod 650. The surgeon beginsmethod 650 by accessingdefective tissue 702, using any suitable surgical method including tissue retraction or minimally invasive surgical techniques, atstep 20. - With
defective tissue 702 thus exposed, surface contour information relating totissue 704 surrounding and includingdefective tissue 702 may be collected at step 22. Step 22 is represented by dashed lines inFIG. 5 to indicate that collection of surface contour information may not be performed, depending on the particular embodiment oforthopaedic system 600 in use and surgeon preference. As described in detail herein, collected surface contour information may be used in conjunction withorthopaedic system 600 to replicate the anatomical surface contour the healthy tissue surroundingdefective tissue 702 after implantation ofcustom implant 700. An exemplary method and system for collecting surface contour of an anatomical surface is disclosed in U.S. patent application Ser. No. 12/191,429, entitled METHOD OF DETERMINING A CONTOUR OF AN ANATOMICAL STRUCTURE AND SELECTING AN ORTHOPAEDIC IMPLANT TO REPLICATE THE ANATOMICAL STRUCTURE incorporated herein by reference above. - With reference to step 24 shown in
FIG. 5 , calibration oftracking system 619 may be performed as described above. Whileexemplary method 650 depicts calibration oftracking system 619 as occurring afterdefective tissue 702 is accessed, methods of utilizingorthopaedic system 600 are possible in which any required calibration ofsignal conversion system 620 may occur prior to accessingdefective tissue 702. Moreover,calibration step 24 is shown in dashed lines to indicate that this step may be eliminated frommethod 650 as required or desired for a particular application. - Next,
excision step 26 and data acquisition step 28 ofexemplary method 650 are performed. In steps 26, 28, the surgeon excisestissue defect 702 while contemporaneously acquiring information (such as data associated with movements or functions of mill 606) relating toresection tool 602. In order to create an accurate cloud or set of data points, data associated with mere movement of resection tool 602 (i.e., whenmill 606 is not in contact with any portion of tibia 703) is distinguished from data associated with the actual excision oftissue defect 702. The surgeon may manually provide this data by providing input to orthopaedic system 600 (i.e., via a button or foot pedal) to start and stop data collection. Alternatively, the load state ofmill 606 may be measured and used to determine whenmill 606 is being used to resect tissue. Where the load state is used for this purpose,resection tool 602 may be calibrated or “taught” the difference between a tissue-resection load state and a free-spinning load state by using resection tool in a controlled environment and correlating collected load state data with the known status (i.e., cutting or not cutting) ofmill 606. - Yet another option is to collect surface contour information, as described in detail above, arid to register this surface contour information to
tibia position marker 609, so that the outer boundaries oftissue 704 are known withinmemory 626 ofcomputer 622. Then, whenmill 606 is observed bydetector 614 passing this calculated outer bound towardstibia 703, data points are collected and recorded. Conversely, ifmill 606 moved past the outer boundary away fromtibia 703, collection and recordation of data points ceases. - As represented in
steps resection tool 602 is stored in memory 626 (step 30) of signal conversion system 620 (FIGS. 1 and 7-9) and converted atstep 32 intoimplant forming commands 629 by conversion software 628 (FIGS. 7-9 ). Instep 34,implant forming commands 629, are used by custom implant forming system 630 (FIGS. 1 and 7-9 ) to generatecustom implant 700, as discussed above. - With
void 712 created andcustom implant 700 generated,custom implant 700 is then implanted intovoid 712. Becausecustom implant 700 corresponds in size and shape to void 712,implant 700 forms a close, custom fit withinvoid 712. However, a surgeon may perform minor reshaping ofimplant 700 and/or void 712 to further refine the fit therebetween. - Optionally, if articular surface 700 a of
implant 700 is elevated above the surrounding bone oftibia 703, articular surface 700 a may be milled atstep 38 to replicate the original contour oftissue 704 in the manner described above. To ensure that this milling creates an articular surface comparable or identical to the original anatomic curvature, implant resurfacing commands 625′ (FIG. 1 ) may be issued toresection tool controller 623 in a similar manner as anatomical shaping commands 625, described above. However, rather than preventingmill 606 from exceeding the allowable tolerances ofvoid 712, implant resurfacing commands 625′ are adapted to prevent any shaping of articular surface 700 a beyond the original surface contour oftissue 704, a virtual model of which was previously generated at step 22. - Surface contour information, collected prior to excising
defective tissue 702, is first translated byconversion software 628 into a series of surface contour tolerance values and stored inmemory 626. During milling of the elevated portion of articular surface 700 a ofcustom implant 700,computer 622 continuously receives newly detected signals 612, 613 a, 613 b and 618 (relating to acquired data associated withmill 606 ofresection tool 602, as described above) which is simultaneously and continuously converted to detectedsignal 621. Detectedsignal 621 is compared to the previously computed surface contour tolerance values byconversion software 628. The results of such comparison indicate whethermill 606 ofresection tool 602 is nearing a violation of surface contour tolerance values. - If such violation is imminent,
computer 622 provides implant resurfacing command 625′ toresection tool controller 623, which in turn causes shutdown oftissue resection tool 602 and/or some visual, audio, or tactile indicator, such as an audible signal to an operator in a similar fashion as described above. One system which may be useable for shaping of articular surface 700 a ofcustom implant 700 is described in U.S. Pat. No. 6,757,582, incorporated by reference above. - An alternative exemplary method of utilizing
orthopaedic system 600, described and depicted herein, is presented inFIG. 6 as method 660. Method 660 includes the steps ofmethod 650, but constrains one or more of the boundaries ofvoid 712 to a predefined value (i.e., resection depth D described above) by way of a feedback loop controllingresection tool 602. - After accessing
step 20, step 40 is added to define the volumetric characteristics ofvoid 712. Inmethod 650,implant 700 is generated based onvoid 712 created duringexcision step 26. In method 660, by contrast, void 712 is itself specified, at least in part, at step 40. While step 40 is shown as occurring after accessingstep 20, it is contemplated that step 40 can occur at any time before the completion ofexcision step 26. - With one or more volumetric characteristics of void 712 (i.e., resection depth D shown in
FIG. 3 ) now defined,excision step 26 and data acquisition andstorage steps 28, 30 proceed as described with respect to method 650 (FIG. 5 ). As the data is stored instep 30, such data is continuously, iteratively compared instep 42 to the boundaries or outer limits of the desired volumetric characteristics ofvoid 712 defined in step 40. If the operative end (i.e., mill 606) ofresection tool 602 is at (or near) this boundary, anatomic shaping command 625 (described in detail above) issues and creates its desired effect, i.e., shutting downresection tool 602 or sounding an alarm. If, on the other hand, theboundary comparison step 42 finds that the operative end ofresection tool 602 is within the predefined volume ofvoid 712,excision step 26, data acquisition step 28 anddata storage step 30 continue. - In some applications, it may be desirable to register
tibia 703 anddefect 702 to a coordinate system within the tracked surgical space, to ensure thatvoid 712 will be properly centered arounddefect 702 after the excision is complete. In such applications, the comparison atstep 42 is not only performed to compare the acquired data points to the volumetric characteristics ofvoid 712, but also compares relative position of the data points to defect 702. Registration can be accomplished by any suitable method, such as by touchingmill 606 to the center ofdefect 702 before excision begins, whiletibia 703 is tracked or immobilized (as described above). By recording this position ofmill 606 within the monitored surgical space,computer 622 is taught the position ofdefect 702 within the monitored surgical space.Computer 622 can therefore “register” or overlay the desired volumetric characteristics ofvoid 712 withdefect 702, and issueimplant forming commands 629 whenevermill 606 is outside of void 712 (and therefore, away from defect 702). - Once anatomic shaping command 625 is generated at
step 42, a second inquiry is made at step 46 as to whethervoid 712 has achieved the desired volumetric characteristics defined in step 40. If the answer to this inquiry is “yes”, i.e., if the resected volume ofvoid 712 matches the desired volume, then the acquired data set is converted intoimplant forming commands 629 and the processes of generating, implanting and (optionally) resurfacingcustom implant 700 proceeds as described above with respect tomethod 650. If, on the other hand, the answer is “no”, i.e., the desired resected volume ofvoid 712 has not yet been achieved, method 660 reverts to excisionstep 26 to continue removing tissue and expandingvoid 712. - Although
orthopaedic system 600 is described herein in the context of creation and implantation ofcustom implant 700, it is contemplated that pre-formed implants may also be used. For example, the dimensional representations ofvoid 712 may be compared to a library of predefined shapes for which pre-formed implants are available, i.e., a standard conical shape. In one alternative embodiment, if the dimensional representations of the shape oftissue 704 excised are within specified tolerances of the shape of an available pre-formed implant,orthopaedic system 600 may alert the user that a cartilage punch or other standard resection tool corresponding to the predefined shape may be used to create void 712 sized to fit such standard implant. In another alternative,resection tool 602 may be controlled by anatomical shaping commands 625, as described in detail above, to create void 712 corresponding to the shape of a pre-formed implant. Systems relating to the use of a library of implants and methods relating to best-fit analyses may be found in U.S. patent application Ser. No. 12/191,429, entitled METHOD OF DETERMINING A CONTOUR OF AN ANATOMICAL STRUCTURE AND SELECTING AN ORTHOPAEDIC IMPLANT TO REPLICATE THE ANATOMICAL STRUCTURE, incorporated by reference above. - While this disclosure has been described as having exemplary designs, the present disclosure can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and which fall within the limits of the appended claims.
Claims (21)
1-20. (canceled)
21. A system for repairing a tissue defect in an anatomical structure, the system comprising:
a resection tool to resect defective tissue;
a tracking system to track movement of the resection tool to collect a set of data points corresponding to a void created by the resection tool;
a signal conversion system to create implant forming commands from the set of data points; and
an implant forming system to:
receive the implant forming commands from the signal conversion system; and
create a custom implant using the implant forming commands, the custom implant sized and shaped to fill the void created by the resection tool.
22. The system of claim 21 , wherein the resection tool has an operative end, the operative end used to resect defective tissue.
23. The system of claim 22 , wherein the operative end of the resection tool comprises at least one of a mill, an oscillating blade, a rotary cutting blade, a retractable blade, a cautery device, a scalpel, or a particulate stream.
24. The system of claim 22 , wherein the operative end of the resection tool moves through a target volume to create the set of data points, the target volume independently moveable with respect to the resection tool.
25. The system of claim 22 , wherein the tracking system is to iteratively compare the void to a desired volumetric characteristic to determine whether the operative end of the resection tool is at a desired boundary, wherein the desired volumetric characteristic is predefined and forms the desired boundary.
26. The system of claim 21 , wherein the tracking system includes:
at least one detector used to collect the set of data points by capturing information from positional markers within a field of view; and
at least one positional marker coupled to the resection tool, the at least one positional marker used to collect the set of data points by identifying a data point and an orientation of the resection tool within the field view of the at least one detector.
27. The system of claim 21 , wherein the signal conversion system includes a processor to convert the set of data points to a virtual three-dimensional volume, the virtual three-dimensional volume used to create the implant forming commands.
28. The system of claim 21 , wherein the signal conversion system is to create the implant forming commands from the set of data points after determining that the set of data points form a complete volumetric representation of the void.
29. The system of claim 21 , wherein the implant forming system includes:
an implant blank;
a turntable to which the implant blank is mountable; and
an implant cutter assembly including a cutter mounted to a robot arm, the cutter moveable through multiple degrees of freedom, wherein the implant cutter assembly removes material from the implant blank as the implant blank is rotated on the turntable to create the custom implant.
30. At least one machine-readable medium including instructions for operation of a computing system, which when executed by a machine, cause the machine to:
track movement of a resection tool to collect a set of data points corresponding to a void created by the resection tool;
create implant forming commands from the set of data points; and
create a custom implant using the implant forming commands, the custom implant sized and shaped to fill the void created by the resection tool.
31. The at least one machine-readable medium of claim 30 , wherein the resection tool has an operative end, the operative end used to resect defective tissue.
32. The at least one machine-readable medium of claim 31 , wherein the operative end of the resection tool comprises at least one of a mill, an oscillating blade, a rotary cutting blade, a retractable blade, a cautery device, a scalpel, or a particulate stream.
33. The at least one machine-readable medium of claim 31 , wherein the operative end of the resection tool moves through a target volume to create the set of data points, the target volume independently moveable with respect to the resection tool.
34. The at least one machine-readable medium of claim 31 , further comprising instructions to iteratively compare the void to a desired volumetric characteristic to determine whether the operative end of the resection tool is at a desired boundary, wherein the desired volumetric characteristic is predefined and forms the desired boundary.
35. The at least one machine-readable medium of claim 30 , wherein the instructions to create the implant forming commands include instructions to convert the set of data points to a virtual three-dimensional volume.
36. The at least one machine-readable medium of claim 30 , wherein the instructions to create the implant forming commands from the set of data points include instructions to create the implant forming commands after determining that the set of data points form a complete volumetric representation of the void.
37. The at least one machine-readable medium of claim 30 , further comprising instructions to issue at least one of an anatomical shaping command or an implant resurfacing command from a resection tool controller in response to a comparison of the set of data points to a desired volumetric profile.
38. A system for repairing a tissue defect in an anatomical structure, the system comprising:
a resection tool to resect defective tissue;
a tracking system to track movement of the resection tool to collect a set of data points corresponding to a void created by the resection tool; and
a signal conversion system to:
create implant forming commands from the set of data points; and
send the implant forming commands to an implant forming system for creation of a custom implant.
39. The system of claim 38 , wherein the implant forming commands are configured to instruct the implant forming system to create the custom implant in a size and shape to fill the void created by the resection tool.
40. The system of claim 38 , wherein the resection tool has an operative end, the operative end used to resect defective tissue.
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Also Published As
Publication number | Publication date |
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US9433471B2 (en) | 2016-09-06 |
US8652148B2 (en) | 2014-02-18 |
US20140135857A1 (en) | 2014-05-15 |
US20110208256A1 (en) | 2011-08-25 |
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